Lange coupler system and method

ABSTRACT

A system and method for the fabrication of high reliability high performance Lange couplers (optionally including capacitors ( 1011 ), inductors ( 1012 ), multi-layer interconnects ( 1013 ), and resistors ( 1014 )) on various thin film hybrid substrate surfaces ( 0501 ) is disclosed. The disclosed Lange coupler method first employs a thin metal layer ( 0502 ) deposited and patterned on the substrate ( 0501 ). This thin patterned layer ( 0502 ) is used to provide both lower electrodes for capacitor structures ( 0603 ) and interconnects ( 0604 ) between upper electrode components. Next, a dielectric layer ( 0705 ) is deposited over the thin patterned layer ( 0502 ) and the dielectric layer ( 0705 ) is patterned to open contact holes ( 0806 ) to the thin patterned layer. The upper electrode layers ( 0907, 0908, 1009, 1010 ) are then deposited and patterned on top of the dielectric ( 0705 ). The resulting Lange coupler structure has significantly improved electrical performance over the prior art, while incorporating overall structural integrity superior to that of the prior art.

CROSS REFERENCE TO RELATED APPLICATIONS Utility Patent Applications

This patent application is a continuation-in-part Utility Patent Application for “INTEGRATED THIN FILM CAPACITOR/INTERCONNECT SYSTEM AND METHOD”, Ser. No. 10/686,128, docket USI-2003-005, filed Oct. 15, 2003, now U.S. Pat. No. ______. Applicants incorporate this parent application by reference and claim benefit pursuant to 35 U.S.C. § 120 for this previously filed patent application.

U.S. Pat. No. ______ (Ser. No. 10/686,128) was a continuation-in-part Utility Patent Application for “INTEGRATED THIN FILM CAPACITOR/INTERCONNECT SYSTEM AND METHOD”, Ser. No. 09/960,796, docket USI-2001-002, filed Sep. 21, 2001, now U.S. Pat. No. 6,761,963. Applicants incorporate this parent application by reference and claim benefit pursuant to 35 U.S.C. § 120 for this previously filed patent application.

Provisional Patent Applications

Applicant claims benefit pursuant to 35 U.S.C. § 119 and hereby incorporates by reference Provisional Patent Application for “INTEGRATED THIN FILM CAPACITOR/INTERCONNECT SYSTEM AND METHOD”, Ser. No. 60/234,135, docket USI-001PP, filed Sep. 21, 2000, and submitted to the USPTO with Express Mail Label EM267139965US.

PARTIAL WAIVER OF COPYRIGHT

All of the material in this patent application is subject to copyright protection under the copyright laws of the United States and of other countries. As of the first effective filing date of the present application, this material is protected as unpublished material.

However, permission to copy this material is hereby granted to the extent that the copyright owner has no objection to the facsimile reproduction by anyone of the patent documentation or patent disclosure, as it appears in the United States Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

REFERENCE TO A MICROFICHE APPENDIX

Not Applicable

FIELD OF THE INVENTION

The present invention provides a system and method for fabricating Lange couplers on hybrid microelectronic substrate surfaces using thin film technology. Specifically, it employs a thin lower bridge conducting electrode layer under a patterned dielectric layer. Conventional thin film conductors are then deposited on top of the dielectric layer to form integrated high performance Lange coupler structures on the same device.

BACKGROUND OF THE INVENTION

Hybrid microelectronic devices such as Lange couplers have been conventionally manufactured on a variety of substrate materials using various techniques such as thick film, low temperature co-fired ceramic (LTCC), and thin film technology. Hybrid devices are used in many microelectronics applications in the defense, medical, communications, computer, automotive, and infrared imaging industries, as well as in many other applications. In all of these industries there is continuous demand for devices that offer improved performance and function, especially at higher electrical frequencies. In order to satisfy these demands, the number of passive devices (capacitors, inductors, and resistors) designed into microelectronic devices continues to grow. For instance, a typical cellular phone product may contain 400 components, with less than 20 devices being active (i.e., semiconductors) and the 380 or more devices being passive devices.

Along with demands for better performance are also requirements to provide products that are less expensive and smaller in size. It is reported that the passive components in a cellular phone product can occupy 80% of the printed circuit board area and account for 70% of the product assembly costs. Thus, there is clear need to reduce the size and cost of the passive devices required in microelectronic devices.

Of the hybrid circuit fabrication techniques, thin film technology is extremely well suited for use in RF/microwave, wireless, and optical transmission technologies because of its ability to provide high quality features, extremely dense packaging, and a large range of integrated features.

The current state of the art in thin film hybrid microelectronic manufacturing offers cost effective, high reliability methods for integrating conductors, inductors, and resistors onto the same thin film hybrid circuit device but not capacitors and interconnects (i.e. connections between devices and multiple layers).

Presently, capacitors are typically purchased individually and attached to the thin film devices using various surface mount die attach techniques. The individual chip capacitors take up valuable space, require much assembly labor, and can decrease reliability due to assembly problems.

Interconnects are often required to interconnect components and devices and to attach to the center of spiral inductors and power splitters such as Lange couplers. Current technology uses wire or ribbon bonding or air bridge type techniques to make individual interconnects. Wire or ribbon bonds can add higher costs and sometimes cause high frequency performance problems due to bond inconsistencies, different bond shapes or the bonds falling over and shorting to conductor lines that they are crossing over. Air bridges are expensive and difficult to produce because of their inherent complexity.

Thus, there is a clear need for a reliable fabrication method that offers both Lange couplers, capacitors, and integrated interconnects. It is especially desirable that this method provides features that are usable from DC to very high operating frequencies. The prior art does not satisfy this need.

A recent approach to the integration of capacitors and interconnects has concentrated on fabricating these devices on silicon wafers. See MARC DE SAMBER, NICK PULSFORD, MARC VAN DELDEN, ROBERT MILSOM; “Low-Complexity MCM-D Technology with Integrated Passives for High Frequency Applications”, The International Journal of Microcircuits and Electronic Packaging, Volume 21, Number 2, Second Quarter 1998, pgs 224-229 (ISSN 1063-1674) (International Microelectronics and Packaging Society).

This paper presented simple concepts for fabricating integrated capacitors, inductors, resistors, and interconnects on silicon wafers. However, processing thin film hybrid substrates offers unique challenges when compared to silicon wafers, and the teachings presented in this prior art are not directly applicable to thin film hybrid substrate processing. Additionally, the integration of reliable Lange coupler structures that can be easily manufactured within this context has not been addressed by the prior art.

DESCRIPTION OF THE PRIOR ART Overview

Two basic techniques have been used in the past to fabricate the “cross-overs” required to build Lange Couplers on integrated hybrid substrates. One technique is to use wire or ribbon bonds as the interconnects, the other technique is to use air bridges to connect the interdigitated fingers of a Lange coupler. Both techniques utilize “cross-overs” to provide interconnection within the Lange coupler structure. The wire bond technique is problematic because each bond has to be applied individually which can lead to reliability and tuning issues. The air bridge technique requires many process steps which leads to high product costs and decreased yields.

Wired Bridge Lange Coupler (0100)

FIG. 1 (0110) schematically illustrates a conventional prior art microstrip Lange coupler as detailed in the text MICROWAVE ENGINEERING, by David M. Pozar, ISBN 0-201-50418-9, 1990, page 431. This structure is schematically illustrated in FIG. 1 (0110) as having an INPUT PORT (0111), THROUGH PORT (0112), COUPLED PORT (0113), and ISOLATED PORT (0114).

A conventional prior art implementation of a Lange coupler is illustrated in FIG. 1 (0120), extracted from U.S. Pat. No. 5,834,991 issued to Joseph B. Mazzochette on Nov. 10, 1998. This structure requires one or more wire bridges or air bridges to implement the Lange coupler function. It is these bridges which present reliability and manufacturability problems in the prior art.

Unfolded Lange Coupler (0200)

FIG. 2 (0200) illustrates a conventional prior art microstrip unfolded Lange coupler as detailed in the text MICROWAVE ENGINEERING, by David M. Pozar, ISBN 0-201-50418-9, 1990, page 431. This structure requires one or more wire bridges or air bridges to implement the Lange coupler function. It is these bridges which present reliability and manufacturability problems in the prior art.

Lange Coupler with Crossover (0300)

FIG. 3 (0300) illustrates a prior art MIM technique implementing a Lange coupler that uses air-bridges to crossover and connect the interdigitated fingers. This technique uses multiple deposition and patterning processes to build up and then cross over to the upper electrode layer.

This method exhibits manufacturing and repeatability problems due to its very complex nature. It is expensive and problematic to produce. It also suffers from reliability problems because the air bridges are vulnerable to collapsing and shorting from handling.

Air-Bridge Interconnects (0300)

In an effort to fabricate integrated interconnects, a “crossover” or “air-bridge” technique has also been employed, as described in FIG. 3 (0300). This technique uses multiple deposition and patterning processes on a substrate to build up and then crossover thick conductor traces to form interconnects. The processes are typically expensive and therefore can usually only be used in high volume production or in specialty applications that are not cost sensitive. Additionally, the air-bridge spans are fragile and can be deformed or collapsed by simple handling. It is also important to note that due to the complex nature of the air-bridge process, it is extremely rare for air-bridge interconnects and air-bridge capacitors to be produced on the same device.

Air-Bridge Interconnects with Support (0400)

A more complex version of the simple air-bridge is to support the crossover span with an underlying insulating material, as illustrated in the prior art Lange coupler of FIG. 4 (0410), extracted from U.S. Pat. No. 5,834,991 issued to Joseph B. Mazzochette on Nov. 10, 1998. Supported crossovers prevent the cross over span from being deformed and causing it to short to the conductor lines underneath. Usually polyimide is used as the supporting insulation. A physical implementation of this type of structure is illustrated in the photomicrograph of FIG. 4 (0420).

The addition of the insulating support under the span increases the complexity and cost of the supported crossover process. It is again important to note that due to the complex nature of the supported air-bridge process, it is extremely rare for supported air-bridge interconnects and air-bridge capacitors to be produced on the same device.

Prior U.S. Patents

The prior art in this area relates generally to the following U.S. Pat. Nos. 3,969,197; 4,002,542; 4,002,545; 4,038,167; 4,062,749; 4,364,099; 4,408,254; 4,410,867; 4,423,087; 4,471,405; 4,599,678; 4,631,633; 5,122,923; 5,258,886; 5,262,920; 5,338,950; 5,390,072; 5,455,064; 5,539,613; 5,587,870; 5,643,804; 5,670,408; 5,685,968; 5,693,595; 5,699,224; 5,708,302; 5,736,448; 5,737,179; 5,745,335; 5,760,432; 5,767,564; 5,781,081; 5,818,079; 5,872,040; 5,874,379; 5,877,533; 5,882,946; 5,883,781; 5,889,299; 5,907,470; 5,912,044; 5,936,831; 5,943,547; 5,973,908; 5,973,911; 5,982,018; 6,001,702; 6,023,407; 6,023,408; 6,040,594; 6,069,388; 6,072,205; 6,075,691.

These patents generally address the following general areas:

-   1. Fabrication of Lange couplers on silicon wafers. Unfortunately,     the manufacturing techniques utilized here are inapplicable to thin     film hybrid substrate fabrication. -   2. Fabrication of Lange couplers on thick film hybrid substrates.     While these techniques do permit Lange coupler fabrication, the     performance of these devices is limited and their manufacturing     yield is generally low due to step coverage problems and/or problems     with crossover bridge spans. -   3. Fabrication of Lange couplers on thick film hybrid substrates     using exotic plating techniques. These systems generally have high     manufacturing costs and lower device performance than the present     invention.     None of the prior art teaches the use of very thin metal patterns     “under” the Lange couplers to avoid step coverage problems and     improve manufacturing yield.

OBJECTIVES OF THE INVENTION

The present invention provides a system and method for fabricating cost effective, high reliability Lange couplers in order to provide the ability to integrate Lange couplers and interconnects along with conductors, capacitors, inductors, and resistors all on the same thin film hybrid microelectronic device. Accordingly, the objectives of the present invention are (among others) to circumvent the deficiencies in the prior art and affect one or more of the following:

-   1. It is an object of this present invention to provide a method for     forming Lange couplers and interconnects on thin film hybrid     microelectronic substrates. This method first employs a thin metal     layer deposited and patterned on the substrate. This thin patterned     layer is used to provide for the interconnects for Lange coupler     structures and other upper electrode components. Next, a dielectric     layer is deposited over the thin patterned layer and the dielectric     layer is patterned to open contact holes to the lower electrode     layer. The upper electrode layers are then deposited and patterned     on top of the dielectric layer to define the conductors (including     Lange coupler structures), resistors, and inductors. Thus, by first     depositing and patterning the thin lower interconnect layer that     becomes encapsulated by a suitable dielectric layer under the thick     upper electrodes, this invention simply and economically solves many     of the problems associated with past methodologies. -   2. According to a further object of the present invention, the lower     electrode and interconnect layer are made of a material that is     mainly gold (Au). -   3. According to a further object of the present invention, the lower     electrode and interconnect layer are made of a material that is     mainly copper (Cu). -   4. According to a further object of the present invention, the lower     electrode and interconnect layer are made of a material that is     mainly silver (Ag). -   5. According to a further object of the present invention, the lower     electrode and interconnect layer are made of a material that is     mainly aluminum (Al). -   6. According to a further object of the present invention, the lower     electrode and interconnect layer are made of one or more metals     selected from a group consisting of tantalum (Ta), tungsten (W),     titanium (Ti), nickel (Ni), molybdenum (Mo), platinum (Pt),     palladium (Pd), or chromium (Cr). -   7. According to a further object of the present invention, the     dielectric layer is made of a material that is mainly silicon     nitride (Si₃N₄). -   8. According to a further object of the present invention, the     dielectric layer is made of a material that is mainly silicon     dioxide (SiO₂). -   9. According to a further object of the present invention, the     dielectric layer is made of a material that is mainly silicon     oxynitride (SiO_(X)N_(X)). -   10. According to a further object of the present invention, the     dielectric layer is made of a material that is mainly aluminum oxide     (Al₂O₃). -   11. According to a further object of the present invention, the     dielectric layer is made of a material that is mainly tantalum     pentoxide (Ta₂O₅). -   12. According to a further object of the present invention, the     dielectric layer is made of a material that consists of a     ferroelectric material that is mainly BaTiO₃, SrTiO₃, BaTiO₃,     PbZrO₃, PbTiO₃, LiNbO₃, or Bi₁₄Ti₃O₁₂. -   13. According to a further object of the present invention, the     dielectric layer is made of a material that is mainly polyimide or     benzocyclobutene. -   14. According to a further object of the present invention, the     substrate material is made of one or more of materials selected from     a group consisting of alumina (Al₂O₃), beryllium oxide (BeO), fused     silica (SiO₂), aluminum nitride (AlN), sapphire (Al₂O₃), ferrite,     diamond, LTCC, or glass.     While these objectives should not be understood to limit the     teachings of the present invention, in general these objectives are     achieved by the disclosed invention that is discussed in the     following sections.

BRIEF SUMMARY OF THE INVENTION

The invention is related in the general area of generating integrated thin film Lange couplers and other passive components along with associated interconnect. To date, the industry has been unable to commercially fabricate a viable integrated Lange coupler with repeatable high frequency performance characteristics and reliability in the thin film industry. The system and method described in the figures and the following text discloses such a system that can be fabricated using conventional thin film technologies at substantially reduced costs over methods currently used within the industry.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the advantages provided by the invention, reference should be made to the following detailed description together with the accompanying drawings wherein:

FIG. 1 illustrates prior art Lange coupler structures;

FIG. 2 illustrates a prior art unfolded Lange coupler structure;

FIG. 3 illustrates a prior art Lange coupler structure implemented with air bridges;

FIG. 4 illustrates prior art Lange coupler structures implemented with air-bridge interconnect structure incorporating crossover span supports;

FIG. 5 illustrates a sectional view for illustration of the process for forming integrated capacitors and interconnects on a substrate (0501) according to the present invention and illustrates the step of metalizing (0502) the substrate (0501) with the lower electrode and interconnect layer (0502);

FIG. 6 illustrates a view similar to FIG. 5 but illustrates a further step of forming the individual lower electrodes (0603) for the capacitors and the interconnects (0604);

FIG. 7 illustrates a view similar to FIG. 6 but illustrates a further step of applying the dielectric layer (0705) on top of the patterned individual lower electrodes and the interconnects;

FIG. 8 illustrates a view similar to FIG. 8 but illustrates a further step of forming contact holes (0806) to the lower electrodes and interconnects;

FIG. 9 illustrates a view similar to FIG. 8 but illustrates a further step of metalizing the top of the dielectric layer (0705) with the conductor (0907, 0908) and optional resistor layers;

FIG. 10 illustrates a view similar to FIG. 9 but illustrates a further step of patterning the conductor layer with the individual upper electrodes (1009), capacitors (1011), spiral inductors (1012), interconnect (1013), and optional resistor elements (1014);

FIG. 11 illustrates an exemplary unfolded Lange coupler structure using the teachings of the present invention;

FIG. 12 illustrates an exemplary Lange coupler structure using the teachings of the present invention;

FIG. 13 illustrates a photomicrograph detail of an exemplary Lange coupler structure using the teachings of the present invention;

FIG. 14 illustrates a variety of exemplary Lange coupler structure topologies illustrating some possible variants of topologies for the present invention;

FIG. 15 illustrates a variety of exemplary Lange coupler structure topologies illustrating some possible variants of topologies for the present invention;

FIG. 16 illustrates an exemplary process flowchart that implements a fabrication method taught by the present invention.

DESCRIPTION OF THE PRESENTLY PREFERRED EXEMPLARY EMBODIMENTS Embodiments are Exemplary

While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detailed preferred embodiment of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiment illustrated.

The numerous innovative teachings of the present application will be described with particular reference to the presently preferred embodiments, wherein these innovative teachings are advantageously applied to the particular problems of an LANGE COUPLER SYSTEM AND METHOD. However, it should be understood that these embodiments are only examples of the many advantageous uses of the innovative teachings herein. In general, statements made in the specification of the present application do not necessarily limit any of the various claimed inventions. Moreover, some statements may apply to some inventive features but not to others. In general, unless otherwise indicated, singular elements may be in the plural and visa versa with no loss of generality.

System Construction (0500, 0600, 0700, 0800, 0900, 1000)

Referring to the system as described in FIGS. 5-10 (0500, 0600, 0700, 0800, 0900, 1000) and method as described in FIG. 16 (1600), a substrate and method for forming same containing integrated Lange couplers, capacitors, inductors and/or interconnects along with conductors and/or resistors will now be described.

[1] Metalization (1601)

As shown in FIG. 5 (0500), a substrate (0501) is metalized (0502) on one or both sides by sputtering, evaporation, or chemical vapor deposition (1601).

This layer (0502) is typically formed of a lower adhesive layer and an upper conducting layer. Key to the success of the present invention is keeping the total thickness of this metalized layer (0502) at or below approximately 1.50 μm. The prior art universally teaches the use of base metalization layers on the order of 2-4 μm in thickness that makes step coverage difficult in all known Lange coupler and capacitor/inductor/interconnect fabrication processes. The present invention breaks with this methodology and utilizes a much thinner adhesive/conducting layer combination to achieve reliable step coverage and superior passive component performance.

The lower adhesive layer is generally very thin (˜0.03-0.05 μm) and is optimally comprised of chromium (Cr), titanium (Ti), or titanium-tungsten (WTi), although other adhesive conducting materials are also known in the art. The purpose of this layer is to generally act as a bonding interface between the substrate (0501) and the conducting layer (0502).

The upper conducting layer is generally thicker (approximately 0.25 μm to approximately 1.40 μm in thickness, limited only by the total thickness of 1.5 μm of the metalized layer (0502) described above) than the lower adhesive layer and may be comprised of any of a wide variety of metals, but preferred embodiments utilize gold (Au), copper (Cu), aluminum (Al), silver (Ag), tantalum (Ta), tungsten (W), titanium (Ti), nickel (Ni), molybdenum (Mo), platinum (Pt), and/or palladium (Pd). The combination of the lower adhesive layer and upper conducting layer serves as the bottom electrode layer (0502) used to form electrical conducting “bridges” for Lange coupler structures.

[2] Align/Expose/Etch Lower Electrodes (1602)

A photoresist (not shown) is then applied, imaged, and the substrate etched (1602) to form the desired patterns for Lange coupler electrical bridges and the lower electrodes of the capacitors (0603) and any interconnects (0604), as shown in FIG. 6 (0600).

[3] Apply Dielectric Layer (1603)

Then, as shown in FIG. 7 (0700), the dielectric layer of silicon nitride (0.3-2.0 μm) (0705) is applied to the entire substrate (0501) surface by chemical vapor deposition techniques (CVD or PECVD) (1603). One skilled in the art will recognize that other dielectric layer materials are possible. While silicon nitride is a preferred dielectric, a wide variety of other materials are anticipated by the present invention and detailed later in this document.

[4] Align/Expose/Etch Contact Holes (1604)

Thereafter, as shown in FIG. 8 (0800), a photoresist (not shown) is then applied, imaged, and the substrate is plasma etched (1604) to form the contact holes (0806) in the dielectric layer (0705) in order to be able to make electrical contact to the Lange coupler electrical bridges and lower electrodes of the capacitors (0603) and the interconnect (0604).

Note also that in many applications it will be advantageous to selectively pattern the dielectric layer to remove certain portions of dielectric under the upper level metalization. This optional selective patterning can easily be accomplished in this same step. Rationales for this selective patterning procedure may be associated with improving the electrical performance of various capacitor/inductor/interconnect/resistor components, as one skilled in the art will readily recognize.

[5] Metalize Substrate to Make Contact With Lower Electrodes (1605)

FIG. 9 (0900) shows that the substrate is then metalized with the upper electrode metal layers by sputtering, evaporation, chemical vapor deposition, and/or electroplating (1605). These metal layers (0907, 0908) are commonly tantalum nitride (to serve as the resistor layer) under WTi (0.05 μm) (0907) under Au (2-5 μm) (0908). These metal layers can be applied and patterned using etcback, plate-up, or lift-off techniques and make contact to the Lange coupler electrical brides and lower electrode and interconnect patterns through the contact holes.

[6] Align/Expose/Etch Upper Electrode/Inductor/Conductor (1606)

Thereupon, as shown in FIG. 10 (1000), photoresist (not shown) is applied, imaged, and the substrate is etched (1606) to form the Lange coupler interdigitated fingers, conductor layer features, upper electrode pads (1009), and optional spiral inductors (1010). One skilled in the art will recognize that a wide variety of spiral inductor geometries are possible using the teachings of the present invention, and are not limited to the specific spiral inductor illustrated (1010).

[7] Optionally Form Resistor Elements (1607)

In FIG. 10 (1000) the resistor elements (1014) are optionally formed by applying photoresist (not shown), imaging the photoresist, and then etching the resistor layer (1607).

Construction Variations

From the foregoing, it will be understood by one skilled in the art that according to the present invention a lower electrode and interconnect layer formed using a high conductivity material such as Au, Ag, Cu, or Al will offer excellent high frequency characteristics.

It will be further understood that according to the present invention the dielectric material and thickness can be chosen to optimize capacitance values and/or breakdown voltage.

It will be further understood that according to the present invention to integrate capacitors and interconnects on a variety of thin film hybrid substrates and surface finishes along with conductors, inductors, and resistor elements.

Summary

In summary, it will be understood by one skilled in the art that according to the present invention it becomes possible to integrate Lange couplers, capacitors, inductors, and/or interconnects on a thin film hybrid substrate along with conductors and/or resistor elements in a wide variety of configurations.

System Embodiments (1100, 1200, 1300)

The present invention can be generally illustrated as applied specifically to Lange couplers as illustrated in FIGS. 11-13 (1100, 1200, 1300) and will now be described in detail.

Uncoupled Lange Coupler (1100)

Referencing the uncoupled Lange coupler structure of FIG. 11 (1100), the present invention teaches a general Lange coupler structure comprising INPUT (1101), THROUGH (1102), COUPLED (1103), and ISOLATED (1104) ports. These port structures (1101, 1102, 1103, 1104) are formed on upper level metallization, while the cross bridges (1111, 1112) are formed on lower level metallization with corresponding upper/lower level metallization via/contacts (1121, 1122, 1123, 1124).

This structure differs significantly from the prior art illustrated in FIGS. 1-4 in that the present invention teaches that the cross bridge interconnects are formed on lower level metallization as opposed to upper level metallization as in the prior art. Significantly, as indicated in FIG. 5 (0500), the lower metallization layer (0502) utilized in formation of the present invention Lange coupler structure is typically formed of a lower adhesive layer and an upper conducting layer.

Key to the success of the present invention is keeping the total thickness of this metalized layer (0502) at or below approximately 1.50 μm. This permits elimination of step coverage problems normally associated with the fabrication of conventional Lange coupler structures as well as drastic improvement of reliability over prior art Lange coupler structures incorporating wire bonding over-bridge interconnects as illustrated in FIG. 3 and/or air bridges as illustrated in the prior art of FIG. 4.

Conventional Lange Coupler (1200)

Referencing the conventional Lange coupler structure of FIG. 12 (1200), the present invention teaches a general Lange coupler structure comprising INPUT (1201), THROUGH (1202), COUPLED (1203), and ISOLATED (1204) ports. These port structures (1201, 1202, 1203, 1204) are formed on upper level metallization, while the cross bridges (1211, 1212, 1213, 1214) are formed on lower level metallization with corresponding upper/lower level metallization via/contacts (1221, 1222, 1223, 1224, 1225, 1226, 1227).

This structure differs significantly from the prior art illustrated in FIGS. 1-4 in that the present invention teaches that the cross bridge interconnects are formed on lower level metallization as opposed to upper level metallization as in the prior art. Significantly, as indicated in FIG. 5 (0500), the lower metallization layer (0502) utilized in formation of the present invention Lange coupler structure is typically formed of a lower adhesive layer and an upper conducting layer.

Key to the success of the present invention is keeping the total thickness of this metalized layer (0502) at or below approximately 1.50 μm. This permits elimination of step coverage problems normally associated with the fabrication of conventional Lange coupler structures as well as drastic improvement of reliability over prior art Lange coupler structures incorporating wire bonding over-bridge interconnects as illustrated in FIG. 3 and/or air bridges as illustrated in the prior art of FIG. 4.

Method (1600)

As described previously, the exemplary method used to fabricate the Lange coupler of the present invention is illustrated in FIG. 16 (1600) and is summarized in the following steps:

-   1. metalize the substrate with a thin metal overcoat (1601); -   2. align/image photoresist and etching to form patterns for lower     Lange coupler bridge conductors and capacitor electrodes and     interconnect (1602); -   3. apply the thin dielectric layer (1603); -   4. apply/image the photoresist and etch to form contact holes     (1604); -   5. metalize substrate to make contact with lower electrodes (1605); -   6. apply/image photoresist and etch to form patterns for Lange     coupler interdigitated fingers and conductor/inductor layer and     upper electrode (1606); and -   7. optionally form resistor elements by applying/imaging photoresist     and etching resistor layer (1607).     Key to this process is the thin application of metalization in     step (1) to allow the use of a thin dielectric layer in step (2) to     minimize the impact of step coverage reliability problems that are     present in the prior art.

System/Method Variations

Material Variations

The present invention is amenable to a wide variety of system/method variations, some of which include the following:

-   1. The lower electrode and interconnect layer may be comprised of     materials that are mainly gold (Au), copper (Cu), silver (Ag),     aluminum (Al). -   2. The lower electrode and interconnect layer may be comprised of     materials that are made of one or more metals selected from a group     consisting of tantalum (Ta), tungsten (W), titanium (Ti), nickel     (Ni), molybdenum (Mo), platinum (Pt), palladium (Pd), or chromium     (Cr). -   3. The dielectric layer may be comprised of materials that are made     of a material that is mainly silicon nitride (Si₃N₄), silicon     dioxide (SiO₂), silicon oxynitride (SiO_(X)N_(X)), aluminum oxide     (Al₂O₃), or tantalum pentoxide (Ta₂O₅). -   4. The dielectric layer may be comprised of materials that that     consists of a ferroelectric material that is mainly BaTiO₃, SrTiO₃,     BaTiO₃, PbZrO₃, PbTiO₃, LiNbO₃, or Bi₁₄Ti₃O₁₂. -   5. The dielectric layer may be comprised of a material that is     mainly polyimide or benzocyclobutene. -   6. The substrate may be comprised of materials that are selected     from a group consisting of alumina (Al₂O₃), beryllium oxide (BeO),     fused silica (SiO₂), aluminum nitride (AlN), sapphire (Al₂O₃),     ferrite, diamond, LTCC, or glass.     Note that while these variations constitute preferred embodiments of     the present invention, they are not limitive of the teachings of the     present invention.

Product By Process

Referring to the system as described in FIGS. 5-10 (0500, 0600, 0700, 0800, 0900, 1000) and method as described in FIG. 16 (1600), the resulting product containing integrated capacitors, inductors and/or interconnects along with conductors and/or resistors will now be discussed.

What is significant to note about the individual capacitors, inductors, and interconnect (fabricated using the method illustrated herein and for which an exemplary flowchart is given in FIG. 16 (1600)), is that the electrical characteristics of these components are superior to that possible with the prior art. This difference in kind is possible because:

-   1. The parasitic inductance associated with the capacitors formed     using the teachings of the present invention is necessarily lower     than that of the prior art. This is because the length of     interconnect required to actually connect the capacitor to the     remainder of the hybrid circuit need not use crossover spans as in     the prior art. These crossover spans tend to add parasitic     capacitance that reduces the self-resonant frequency of the     capacitor. -   2. Additionally, the parasitic resistance of the capacitor     structures is reduced as compared to the prior art because crossover     spans and additional interconnect required by the prior art has a     finite resistance which reduces the quality factor (Q) of the     capacitor structure. This parasitic resistance is well known by one     skilled in the art as “effective series resistance” and is     necessarily a degradation of device performance. -   3. The parasitic capacitance associated with the inductors and     interconnect using the teachings of the present invention is     significantly lower than that of the prior art. This is in part     because the prior art has difficulty in controlling the dielectric     thickness of the sidewalls of the upper layer conducting layers. -   4. The present invention has significantly better reliability and     manufacturability because of the improvement in step coverage as     compared to the prior art. The potential for sidewall punchthrough     or shorting is a significant drawback of the prior art. This     potential defect reduces manufacturing yields, causes failures in     the field, and generally increases the final cost of the     manufactured hybrid system. -   5. Note that since the reliability of a system containing multiple     capacitors, inductors, and interconnects is determined by the     weakest link in the system, an large array of hybrid components     having poor individual reliability drastically increases the cost of     the overall system because of the reduced overall system     reliability. -   6. Note that in space-constrained designs and also high performance     designs, the ability to overlap ground contact vias (1104) with an     overlapping capacitor structure increased the area efficiency and     high frequency performance of bypass/decoupling/filtering capacitor     structures. This is a significant performance improvement over the     prior art. -   5 One skilled in the art will no doubt observe other advantages to     the present invention as compared to the prior art.

Exemplary System Applications Overview

While a wide variety of system applications are amenable to use of the present invention, several are preferred and will now be discussed. Discussion of these applications in no way limits the scope of the present invention.

Lange Coupler Structure Not Limitive (1400, 1500)

The four port interdigitated Lange coupler structure developed by Dr. Julius Lange around 1969 is widely used as a power combiner and splitter in RF amplifiers as well as mixers and modulators. The ports on this prototypical Lange coupler structure are generally termed INPUT PORT, THROUGH PORT, COUPLED PORT, and ISOLATED PORT. The general structure of this device permits coupling derived from closely spaced transmission lines, such as microstrip lines. Typically the number of conductors or fingers (N) is even. Geometries of N=6 (1401), N=6 (1402), and N=4 (1403) are generally illustrated in FIG. 14 (1400) and additional examples of N=4 (1501), N=6 (1502), and N=8 (1503) are shown in FIG. 15 (1500). The length of the fingers is set by the desired center frequency (Fo) of the filter. The device is relatively broadband, with flat frequency response (Fo). The finger length is equal to the quarter wavelength of Fo in the substrate.

The present invention teaches an improved structure for Lange couplers as applied to thin film hybrid microelectronic substrates. The present invention does not limit the scope of the term “Lange coupler structure” to the geometric structures illustrated in FIGS. 1-4. The Lange coupler structure concept as illustrated in these figures provides for sets of “interdigitated fingers” which are then “bridged” by some electrical connecting means. As illustrated by the exemplary topologies in FIG. 14 (1401, 1402, 1403) and FIG. 15 (1501, 1502, 1503), the number of interdigitated fingers and the number of crossovers may vary widely with the implementation of the particular Lange coupler design without diverging from the teachings of the present invention. The term “Lange coupler structure” is deemed to include any of these geometric topologies consistent with the teachings of the present invention as described herein.

The present invention provides for an improved methodology of implementing the “bridges” between the “interdigitated fingers” by providing a method of accomplishing the electrical connecting means that is both easier to manufacturer as well as providing a higher reliability level than prior art connecting means. The present invention specifically teaches than the “bridges” may be constructed using a metalized “bridge” that is formed below the main “interdigitated fingers”, comprising a lower adhesive layer and an upper conducting layer. Key to the success of the present invention is keeping the total thickness of this metalized bridge layer at or below approximately 1.50 μm.

Thus, the present invention teaches that any conventional Lange coupler structure can be constructed using lower metalized crossover bridges comprising a lower adhesive layer and an upper conducting layer having a sum total thickness at or below approximately 1.50 μm. After dielectric application and patterning, the “interdigitated fingers” of the Lange coupler are patterned in top level metal and connected to the lower level bridge metallization with the use of vias and/or contacts penetrating the dielectric layer.

Exemplary System Modifications Intermediary Adhesion Layer(s)

The present invention anticipates system augmentation in a variety of ways to improve performance and/or reliability via the use of one or more intermediary adhesion layers. As indicated in FIG. 5 (0500), the metallization layer (0502) is typically formed of a lower adhesive layer and an upper conducting layer. Key to the success of the present invention is keeping the total thickness of this metalized layer (0502) at or below approximately 1.50 μm.

To improve overall reliability between the upper conducting layer and subsequent layers (such as silicon nitride), it is often advantageous to incorporate a tungsten-titanium (WTi) or other top adhesion (adhesive) layer on top of the bottom electrode upper conducting layer. This additional adhesion layer in many circumstances prevents the silicon nitride (or other topical layer) from cracking and delaminating from the bottom electrode upper conducting layer when the system is exposed to heat and/or stress. One skilled in the art will recognize that substitutions for the silicon nitride layer and/or the titanium-tungsten (WTi) adhesion layer (such as chromium (Cr) or titanium (Ti)) can be made with no loss of generality in the teachings of the present invention.

CONCLUSION

A system and method for the fabrication of high reliability high performance Lange couplers (optionally including capacitors (1011), inductors (1012), multi-layer interconnects (1013), and resistors (1014)) on various thin film hybrid substrate surfaces (0501) has been disclosed.

The disclosed Lange coupler method first employs a thin metal layer (0502) deposited and patterned on the substrate (0501). This thin patterned layer (0502) is used to provide both lower electrodes for capacitor structures (0603) and interconnects (0604) between upper electrode components. Next, a dielectric layer (0705) is deposited over the thin patterned layer (0502) and the dielectric layer (0705) is patterned to open contact holes (0806) to the thin patterned layer. The upper electrode layers (0907, 0908, 1009, 1010) are then deposited and patterned on top of the dielectric (0705).

The resulting Lange coupler structure has significantly improved electrical performance over the prior art, while incorporating overall structural integrity superior to that of the prior art. 

1. A Lange coupler system comprising: (a) a thin film hybrid substrate; (b) a lower bridge conductor, electrode, and interconnect layer formed on said thin film hybrid substrate, said layer further comprising a lower adhesive layer and an upper conducting layer having a sum total thickness less than or equal to 1.5 microns. (c) a dielectric layer deposited on top of the said patterned lower electrode and interconnect layer; and (d) an upper electrode layer further comprising interdigitated fingers formed on said dielectric layer; wherein said upper conducting layer is approximately 1-6.0 microns thick; said upper conducting layer forms electrical connections between said interdigitated fingers; said interdigitated fingers when connected to said upper conducting layer form a Lange coupler structure.
 2. The Lange coupler system of claim 1, wherein said lower adhesive layer is approximately 0.03 to 0.05 microns thick.
 3. The Lange coupler system of claim 1, wherein said lower adhesive layer comprises chromium.
 4. The Lange coupler system of claim 1, wherein said lower adhesive layer comprises titanium.
 5. The Lange coupler system of claim 1, wherein said lower adhesive layer comprises titanium-tungsten.
 6. The Lange coupler system of claim 1, wherein said upper conducting layer comprises silver.
 7. The Lange coupler system of claim 1, wherein said upper conducting layer comprises aluminum.
 8. The Lange coupler system of claim 1, wherein said upper conducting layer comprises gold.
 9. The Lange coupler system of claim 1, wherein said upper conducting layer comprises copper.
 10. The Lange coupler system of claim 1, wherein said lower electrode and interconnect layer further comprises silver.
 11. The Lange coupler system of claim 1, wherein said lower electrode and interconnect layer further comprises aluminum.
 12. The Lange coupler system of claim 1, wherein said lower electrode and interconnect layer further comprises gold.
 13. The Lange coupler system of claim 1, wherein said lower electrode and interconnect layer further comprises copper.
 14. The Lange coupler system of claim 1, wherein said lower electrode and interconnect layer is selected from the group consisting of tantalum, tungsten, titanium, nickel, molybdenum, platinum, palladium, and chromium.
 15. The Lange coupler system of claim 1, wherein said dielectric layer is selectively patterned.
 16. The Lange coupler system of claim 1, wherein said dielectric layer further comprises silicon nitride.
 17. The Lange coupler system of claim 1, wherein said dielectric layer further comprises silicon dioxide.
 18. The Lange coupler system of claim 1, wherein said dielectric layer further comprises silicon oxynitride.
 19. The Lange coupler system of claim 1, wherein said dielectric layer further comprises aluminum oxide.
 20. The Lange coupler system of claim 1, wherein said dielectric layer further comprises tantalum pentoxide.
 21. The Lange coupler system of claim 1, wherein said dielectric layer further comprises a ferroelectric material.
 22. The Lange coupler system of claim 21, wherein said ferroelectric material is BaTiO₃.
 23. The Lange coupler system of claim 21, wherein said ferroelectric material is SrTiO₃.
 24. The Lange coupler system of claim 21, wherein said ferroelectric material is PbZrO₃.
 25. The Lange coupler system of claim 21, wherein said ferroelectric material is PbTiO₃.
 26. The Lange coupler system of claim 21, wherein said ferroelectric material is LiNbO₃.
 27. The Lange coupler system of claim 21, wherein said ferroelectric material is Bi₁₄Ti₃O₁₂.
 28. The Lange coupler system of claim 1, wherein said dielectric layer further comprises polyimide.
 29. The Lange coupler system of claim 1, wherein said dielectric layer further comprises benzocyclobutene.
 30. The Lange coupler system of claim 1, wherein said substrate material is selected from the group consisting of alumina, beryllium oxide, fused silica, aluminum nitride, sapphire, ferrite, diamond, LTCC, and glass.
 31. The Lange coupler system of claim 1, further comprising an adhesion layer on top of said upper conducting layer.
 32. The Lange coupler system of claim 1, further comprising an adhesion layer comprising titanium-tungsten on top of said upper conducting layer.
 33. The Lange coupler system of claim 1, further comprising an adhesion layer comprising chromium on top of said upper conducting layer.
 34. The Lange coupler system of claim 1, further comprising an adhesion layer comprising titanium on top of said upper conducting layer.
 35. A thin film Lange coupler method comprising: (1) thinly metalizing a substrate with a lower bridge conductor electrode interconnect layer formed on said thin film hybrid substrate, said layer further comprising a lower adhesive layer and an upper conducting layer having a sum total thickness of less than or equal to 1.5 microns; (2) applying/imaging photoresist and etching to form metal patterns on said substrate for lower bridge conductor electrode interconnect; (3) applying a thin dielectric layer to said metal patterns; (4) applying/imaging photoresist and etching to form contact holes in said dielectric layer and optionally selectively patterning said dielectric layer; (5) metalizing said substrate to make contact with said lower bridge conductor electrode interconnect; (6) applying/imaging photoresist and etching to form patterns for upper interdigitated fingers and interconnect conductors; wherein said upper conducting layer is approximately 0.25-1.40 microns thick; said upper conducting layer forms electrical connections between said interdigitated fingers; said interdigitated fingers when connected to said upper conducting layer form a Lange coupler structure.
 36. The Lange coupler method of claim 35, wherein said lower adhesive layer is approximately 0.03 to 0.05 microns thick.
 37. The Lange coupler method of claim 35, wherein said lower adhesive layer comprises chromium.
 38. The Lange coupler method of claim 35, wherein said lower adhesive layer comprises titanium.
 39. The Lange coupler method of claim 35, wherein said lower adhesive layer comprises titanium-tungsten.
 40. The Lange coupler method of claim 35, wherein said upper conducting layer comprises silver.
 41. The Lange coupler method of claim 35, wherein said upper conducting layer comprises aluminum.
 42. The Lange coupler method of claim 35, wherein said upper conducting layer comprises gold.
 43. The Lange coupler method of claim 35, wherein said upper conducting layer comprises copper.
 44. The Lange coupler method of claim 35, wherein said lower electrode and interconnect layer further comprises silver.
 45. The Lange coupler method of claim 35, wherein said lower electrode and interconnect layer further comprises aluminum.
 46. The Lange coupler method of claim 35, wherein said lower electrode and interconnect layer further comprises gold.
 47. The Lange coupler method of claim 35, wherein said lower electrode and interconnect layer further comprises copper.
 48. The Lange coupler method of claim 35, wherein said lower electrode and interconnect layer is selected from the group consisting of tantalum, tungsten, titanium, nickel, molybdenum, platinum, palladium, and chromium.
 49. The Lange coupler method of claim 35, wherein said dielectric layer is selectively patterned.
 50. The Lange coupler method of claim 35, wherein said dielectric layer further comprises silicon nitride.
 51. The Lange coupler method of claim 35, wherein said dielectric layer further comprises silicon dioxide.
 52. The Lange coupler method of claim 35, wherein said dielectric layer further comprises silicon oxynitride.
 53. The Lange coupler method of claim 35, wherein said dielectric layer further comprises aluminum oxide.
 54. The Lange coupler method of claim 35, wherein said dielectric layer further comprises tantalum pentoxide.
 55. The Lange coupler method of claim 35, wherein said dielectric layer further comprises a ferroelectric material.
 56. The Lange coupler method of claim 55, wherein said ferroelectric material is BaTiO₃.
 57. The Lange coupler method of claim 55, wherein said ferroelectric material is SrTiO₃.
 58. The Lange coupler method of claim 55, wherein said ferroelectric material is PbZrO₃.
 59. The Lange coupler method of claim 55, wherein said ferroelectric material is PbTiO₃.
 60. The Lange coupler method of claim 55, wherein said ferroelectric material is LiNbO₃.
 61. The Lange coupler method of claim 55, wherein said ferroelectric material is Bi₁₄Ti₃O₁₂.
 62. The Lange coupler method of claim 35, wherein said dielectric layer further comprises polyimide.
 63. The Lange coupler method of claim 35, wherein said dielectric layer further comprises benzocyclobutene.
 64. The Lange coupler method of claim 35, wherein said substrate material is selected from the group consisting of alumina, beryllium oxide, fused silica, aluminum nitride, sapphire, ferrite, diamond, LTCC, and glass.
 65. The Lange coupler method of claim 35, further comprising an adhesion layer on top of said upper conducting layer.
 66. The Lange coupler method of claim 35, further comprising an adhesion layer comprising titanium-tungsten on top of said upper conducting layer.
 67. The Lange coupler method of claim 35, further comprising an adhesion layer comprising chromium on top of said upper conducting layer.
 68. The Lange coupler method of claim 35, further comprising an adhesion layer comprising titanium on top of said upper conducting layer.
 69. The Lange coupler product of the thin film fabrication method comprising: (1) thinly metalizing a substrate with a lower bridge conductor electrode interconnect layer formed on said thin film hybrid substrate, said layer further comprising a lower adhesive layer and an upper conducting layer having a sum total thickness of less than or equal to 1.5 microns; (2) applying/imaging photoresist and etching to form metal patterns on said substrate for lower bridge conductor electrode interconnect; (3) applying a thin dielectric layer to said metal patterns; (4) applying/imaging photoresist and etching to form contact holes in said dielectric layer and optionally selectively patterning said dielectric layer; (5) metalizing said substrate to make contact with said lower bridge conductor electrode interconnect; (6) applying/imaging photoresist and etching to form patterns for upper interdigitated fingers and interconnect conductors; wherein said upper conducting layer is approximately 0.25-1.40 microns thick; said upper conducting layer forms electrical connections between said interdigitated fingers; said interdigitated fingers when connected to said upper conducting layer form a Lange coupler structure.
 70. The Lange coupler product of claim 69, wherein said lower adhesive layer is approximately 0.03 to 0.05 microns thick.
 71. The Lange coupler product of claim 69, wherein said lower adhesive layer comprises chromium.
 72. The Lange coupler product of claim 69, wherein said lower adhesive layer comprises titanium.
 73. The Lange coupler product of claim 69, wherein said lower adhesive layer comprises titanium-tungsten.
 74. The Lange coupler product of claim 69, wherein said upper conducting layer comprises silver.
 75. The Lange coupler product of claim 69, wherein said upper conducting layer comprises aluminum.
 76. The Lange coupler product of claim 69, wherein said upper conducting layer comprises gold.
 77. The Lange coupler product of claim 69, wherein said upper conducting layer comprises copper.
 78. The Lange coupler product of claim 69, wherein said lower electrode and interconnect layer further comprises silver.
 79. The Lange coupler product of claim 69, wherein said lower electrode and interconnect layer further comprises aluminum.
 80. The Lange coupler product of claim 69, wherein said lower electrode and interconnect layer further comprises gold.
 81. The Lange coupler product of claim 69, wherein said lower electrode and interconnect layer further comprises copper.
 82. The Lange coupler product of claim 69, wherein said lower electrode and interconnect layer is selected from the group consisting of tantalum, tungsten, titanium, nickel, molybdenum, platinum, palladium, and chromium.
 83. The Lange coupler product of claim 69, wherein said dielectric layer is selectively patterned.
 84. The Lange coupler product of claim 69, wherein said dielectric layer further comprises silicon nitride.
 85. The Lange coupler product of claim 69, wherein said dielectric layer further comprises silicon dioxide.
 86. The Lange coupler product of claim 69, wherein said dielectric layer further comprises silicon oxynitride.
 87. The Lange coupler product of claim 69, wherein said dielectric layer further comprises aluminum oxide.
 88. The Lange coupler product of claim 69, wherein said dielectric layer further comprises tantalum pentoxide.
 89. The Lange coupler product of claim 69, wherein said dielectric layer further comprises a ferroelectric material.
 90. The Lange coupler product of claim 89, wherein said ferroelectric material is BaTiO₃.
 91. The Lange coupler product of claim 89, wherein said ferroelectric material is SrTiO₃.
 92. The Lange coupler product of claim 89, wherein said ferroelectric material is PbZrO₃.
 93. The Lange coupler product of claim 89, wherein said ferroelectric material is PbTiO₃.
 94. The Lange coupler product of claim 89, wherein said ferroelectric material is LiNbO₃.
 95. The Lange coupler product of claim 89, wherein said ferroelectric material is Bi₁₄Ti₃O₁₂.
 96. The Lange coupler product of claim 69, wherein said dielectric layer further comprises polyimide.
 97. The Lange coupler product of claim 69, wherein said dielectric layer further comprises benzocyclobutene.
 98. The Lange coupler product of claim 69, wherein said substrate material is selected from the group consisting of alumina, beryllium oxide, fused silica, aluminum nitride, sapphire, ferrite, diamond, LTCC, and glass.
 99. The Lange coupler product of claim 69, further comprising an adhesion layer on top of said upper conducting layer.
 100. The Lange coupler product of claim 69, further comprising an adhesion layer comprising titanium-tungsten on top of said upper conducting layer.
 101. The Lange coupler product of claim 69, further comprising an adhesion layer comprising chromium on top of said upper conducting layer.
 102. The Lange coupler product of claim 69, further comprising an adhesion layer comprising titanium on top of said upper conducting layer. 